JIPM-TPM.Sample-Forms-Editing-2

DR Standards (2nd and 3rd DR 8•1 2-5
Checksheet)

2nd and 3rd DR Checksheet (Function Development)

Product Name DR Member’s Dept.: 　　　　　　　Name:
No. DR Item
1 Evaluation of Check Point Evaluation (5 Levels) Opinion

basic plan Evaluation of 5 4 3 2 1
development Good 2 Problem
2 Evaluation of schedule plan
design Evaluation of 54 3 2 1
solutions to Countermeasure 2 Not yet.
3 Evaluation of items pointed 2
quality out in 1st DR completed. 2 1
Evaluation of Problem
4. Marketability basic design 5 4 3
specifications Good 1
5. Evaluation of Evaluation of Problem
business ability basic structure 543
Evaluation of Good 1
6. Evaluation of proprietary New.
production technology 543
engineering Reliability In use. Partial use. 1
evaluation ≤ 70
Overall Judgment Level of 54 3
attainment (%) ≥ 90 80
Evaluation of
quality control 54321
items Good Problem
Evaluation of
safety and 54321
maintainability Good Problem
Evaluation of
environmental 54321
affect (listing Good Problem
materials, etc.)
Match with Adequate Right Does not
market needs 54 direction match
Investigation of Big difference. 21
rival products, 3 No difference.
technical
differentiation 54 3 21
Patent search No problem. Possible Serious problem.
Adequate
Outlook on ≥90% Impossible
target cost ≥ 95% ≤ 70%
achievement
Outlook on profit Adequate So-so Impossible
Cost ratio in 3 ≤85 90-95 100+
yrs
Scope of sales >100 100-50 50-10 10-1 >1
after 3 yrs.
(¥million/year) 54321
Evaluation of No problem. Not OK
critical
technology in OK OK with Not OK
prod. conditions
engineering
Proceed to next
step

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Diagnosis Checksheet 8•1 2-6

Diagnosis Checksheet

Date of Diagnosis___/___/___
Diagnosed By________________

At stage when basic design is complete.
Product: Newly developed version of an existing product

Points Diagnosed: The product concept 10 years from now is clear, and the tentative targets for QCD
have been set.

Theme Name:______________________________________________

Development Department Name:___________________________

Results of Diagnosis (Please circle the appropriate answer. Circle the middle answer if neither extreme fits).

Evaluation Item 5 4 3 2 1 Evaluation Comments

1 Product differentiation Major Some No diff.
(compared to other

companies)

2 Match with customer Adequate Right Direction Doubtful
needs

3 Target cost level Major Some No diff.
(% reduced from current (30% +) (10-20%)

cost level)

4 Timing for completion of Ahead of Meeting Behind
development of functions customer customer

needs. needs.

5 Sales volume after 3 years >100 100-50 50-10 10-1 >1
(¥ millions/year)

6 Development status at Undevel- Sales within Mass prod.
other companies oped 3 years stage

7 Outlook on technical Adequate Possible Difficult to
achievement of new achieve.

functions

8 Effect on current Can use Can use Need new.
equipment as is. with

modification.

Overall Judgment and Comments OK Not OK
Proceed to next step (basic design):

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Design

(Failure Mode and

Our Part No. Development Code Model Date of Analysi
Manufacturer Part No. Deliver To Analyzed By
Manufacturer Part Name
Before C

No. Part Name Part Function Failure Mode Effect of Failure Cause of Failure
(Part No.)
(System) Frequency

Date of Analysis Description, Analysis By Change Sequence Date

FMEA Design FMEA Chart

d Effect Analysis)

is Approval Check In Charge No.___________

Date Created
___/___/___

Countermeasure After Countermeasure

Degree of Effect Description of Deadline Dept. in Remarks
Degree of Detection Treatment Charge of
Importance Treatment
Frequency
Degree of Effect
Degree of Detection
Importance

8•1

of Analysis Description, Analysis By Change Sequence 3-7

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Critical [Bottleneck] Technology Registra

Development Theme Name: Product Name: SOP [Lau
Description
Critical [Bottleneck] Relevant Rank
Diffic
No. Items Fields

[How to Fill Out Form] 2. Ran
1. Relevant Field S: Hard-
(1) Processing accuracy and configuration (2) New materials (3) Surface treatment A: Undev
(4) Heat treatment (5) Process method (6) Measurement technology (7) Sealing method B: Not-ye
(8) Lubrication (9) Other

ation Control Chart Critical Technology Registration
Control Chart
Date Prepared: ____________________________
Department: ______________________________

unch] Date:

k of Degree of Effect Registration Date Main Dept. in Completion Remarks
culty Charge Deadline
QC

8•1

nk of Difficulty 3. Degree of Effect 3-8
-to-develop technology Circle the column which critical technology affects the
veloped technology most, Q or C.
et-applied technology
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Critical [Bottleneck] Technol

Development Theme: Product Name: SOP [Lau
Items Studied Development Sch
Critical [Bottleneck]
No. Items

[How to Fill Out Form]
1. Reporting Periods

*1st Time: when functions have been developed.
*2nd Time: when mass production specifications have been established.

logy Development Plan Critical Technology Development Plan

Date Prepared: ____________________________
Department: ______________________________

unch] Date:

hedule Main Dept. in Charge Evaluation Remarks
(Person in Charge)

8•1

3-9

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ER Standards (1st ER Checksheet) 8•1 3 - 10

1st ER Checksheet

Date of Diagnosis___/___/___
Diagnosed By________________

Items to Be Points to be Checked Main Reporter Evaluation

Checked

Identification of 1 Is new production engineering Production Eng.

Critical [Bottleneck] development necessary?

Technology 2 Is new manufacturing technology Production Eng.

development necessary?

3 Is new development needed for quality Qual. Assurance,

control?

4 Is the plan to handle the above issues Production Eng.

appropriate? Quality Assurance

Process Design 1 Are processes (line) and process methods Production Eng.

Concept appropriate?

2 Are facilities, jigs/tools, measuring Production Eng.

equipment, and dies appropriate?

3 Is anything missing from the main problem Production Eng.

[FUGUAI] items?

4 Is target production capacity and amount Production Eng.

of manpower appropriate?

5 Is the preparation plan easy to achieve? Production Eng.

Division of In-house 1 Is division of in-house and subcontracted Production Eng.
and Subcontracted 2 processing appropriate for mass
Processing production? Production Eng.
Are in-house processing departments Design
3 appropriate for mass production? Production Eng.
Are process instructions clear for mass
4 production?
Among subcontracted parts, are
technologically questionable parts clearly
known?

[Notes for the “Evaluation” column] O: good, ∆: basically OK, X: must be investigated.

Comments

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Diagnosis Checksheet 8•1 3 - 11

Diagnosis Checksheet

Date of Diagnosis___/___/___
Diagnosed By________________

At stage when basic design is complete.
Product: Newly developed version of an existing product

Points Diagnosed: Through the design and prototype manufacture of the planned product, are we ready
to mass produce the product from the perspectives of quality, cost, and processes?

Theme Name:______________________________________________

Development Department Name:___________________________

Results of Diagnosis (Please circle the appropriate answer. Circle the middle answer if neither extreme fits).

Evaluation Item 5 4 3 2 1 Evaluation Comments

1 Product differentiation Major Some No diff.
(technical capability)

2 Match with customer Adequate Right Direction No match
needs

3 Outlook on performance Adequate So-so Bad outlook
and reliability (rate of ≥90% ≥80% Needs work.

achievement)

4 Outlook for achievement Adequate So-so Bad outlook
of critical technology (rate ≥90% ≥80% Needs work.

of achievement)

5 Outlook on target cost Adequate Possible Impossible
achievement (rate of ≥ 95% 90% ≤ 70%

achievement)

6 Outlook on profit Adequate So-so Impossible
(Cost ratio in 3 years) ≤85 90-95 100+

7 Scope of sales >100 100-50 50-10 10-1 >1
after 3 years

(¥ million/year)

Overall Judgment and Comments OK Not OK
Proceed to next step (production design):

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Initial-Phase Production Control 8•1 4 - 12
Commencement Declaration
Sheet/Conclusion Authorization Sheet

Initial-Phase Production Control
Commencement Declaration Sheet/Conclusion Authorization Sheet

Commencement No. Sheet No.

Commencement Declaration: We declare Quality Assurance Commencement Declaration Issue Date
commencement of initial-phase product control of Dept.
the following products.

Customer Name Product No. Department In Charge
Organization Name Product Name Manager

Initial Control Forecast Technology Evaluation Production Control
Product Information No. No. Schedule No.

Reason for Commencement

Control Items and Scope

Distribution Rough Schedule
Initial-Phase I Activity Evaluation

Quality Conclusion Authorization Issue Date:
Assurance
Conclusion Authorization: We authorize conclusion of the Department Manager In Charge
initial-phase product control of the respective product. Dept.

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Drawing Study F

Manufactured In-house / Outsourced (Circle one). Name of Issuing Group
___/___/___
Product Name
Product No.
Desired Date of Response Date: _/_/_
to Design Dept.

Problem Areas in Production Processes Proposed Counterme
(Hard-to-make, problems with equipment, (Proposals for improvem
standardization, quality assurance, etc.)
problem areas at

Predicted Approximately
Effect
Approximately

Desired Response Date

Feedback Chart No.___________ Drawing Study Feedback Chart

Development Code ( ) Development step shown inside parenthesis.

p Studying Dept. Name of Responding Group
___/___/___ ___/___/___

easures Design Engineering Response
ments to the (Plans to incorporate countermeasures into

left.) production drawings).

8•1

¥/unit 4 - 13
¥/unit
___/___/___

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Process FM

(Failure Mode and

Ca

Our Part No. Development Code Mo
Manufacturer Part No. Process Name In-house or Outsourced Analysis Date
Manufacturer Part Name In-house Outsourced Analyzed By

Before C

No. Process Process Function Failure Mode Effect of Failure Cause of Failure

Name (anticipated

problem) Frequency

Date of Analysis Description, Analysis By Change Sequence A

MEA Chart Process FMEA Chart

d Effect Analysis)

No._______________

ategory Heavy/Special Original Dev. Function
odel/Year General
Date Prepared
Approved By Checked By In Charge ___/___/___

Countermeasure After Countermeasure

Degree of Effect Critical Description of Date Dept. in
Degree of Detection Points Treatment Charge of
Importance (current Treatment
Frequency control (description of
Degree of Effect status) countermeasure)
Degree of Detection
Importance

8•1

Analysis Date Description, Analysis By Change Sequence 4- 14

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ER Standards (2nd ER Checksheet) 8•1 4 - 15

2nd ER Checksheet

Date of Diagnosis___/___/___
Diagnosed By________________

Items to Be Points to be Checked Main Reporter Evaluation
Checked
1 Is treatment of items of concern during 1st Prod. Engineering
Process Design
Plan ER appropriate?

Preparation of 2 Are planned equipment capacity and Prod. Engineering
Equipment and
Jigs/Tools production capacity appropriate?

Preparation of 3 Is the amount of planned manpower Prod. Engineering
Standard
Documents appropriate?

Operator Education 4 Is the layout appropriate? Prod. Engineering
and Training
1 Can equipment, jigs/tools, and dies be Prod. Engineering

prepared?

2 Can quality assurance equipment and Qual. Assurance

jigs/tools be prepared?

3 Are there any inadequate jigs/tools? -

4 Is equipment easy to handle (for Prod. Engineering

manufactureability and safety)?

5 Can functions be adequately maintained? Prod. Engineering

6 Must spare parts be prepared? Prod. Engineering

1 Are work standards and inspection Prod. Eng./QA

standards prepared?

2 Do the above documents match the QA-M Prod. Eng./QA

control process charts?

3 Are Key Point Cards prepared? Manufacturing

1 Is there a plan for education and training? Manufacturing

Is the focus of education and training

2 appropriate? Manufacturing

[Notes for the “Evaluation” column] O: good, ∆: basically OK, X: must be investigated.

Comments

© JIPM

DR Standards (4th DR Checksheet) 8•1 4 - 16

4th DR Checksheet (Production Design)

Product Name DR Member’s Dept.: 　　　　　　 Name:
No. DR Item
1 Evaluation of Check Point Evaluation (5 Levels) Opinion

basic plan Evaluation of 5 4 3 21
development Good 3 Problem
2 Evaluation of schedule plan
design Evaluation of 54 3 21
solutions to Countermeasure 3 Not yet.
3 Evaluation of items pointed 3
quality out in 2nd and completed. 3 21
3rd DR 90 Problem
4. Evaluation of Evaluation of 5 4 3
serviceability design function Good 3 21
specifications Not within spec.
5. Marketability Evaluation of 54 3
performance Adequate 3 21
6. Evaluation of specifications Not yet
business ability Degree of 54
drawing Complete 21
7. Evaluation of completeness ≤ 80
production Reliability 54
engineering evaluation 100 21
Level of Incomplete
Overall Judgment attainment (%) 54
Evaluation of Adequate 21
failure analysis 54 Incomplete
(FMEA, FTA) Adequate
Level of 21
completeness of 5 4 Dangerous
service Good
diagrams 21
Evaluation of 54 No difference.
safety and ease Big difference.
of operation
Investigation of
rival products,
technical
differentiation

Patent search 5 4 3 2 1

No problem. Serious problem.

Outlook on Adequate Possible Impossible

target cost 100% 95% ≤ 80%
achievement

Outlook on profit Adequate So-so Impossible
90-95 100+
Cost ratio in 3 ≤85

yrs

Outlook on sales Agree with Agree Big diff. with
price customer in-house customer
Evaluation of 54
problems with No prob. 3 21
manufacturing
equipment 54 Solution Possible Not
Achievement of Achieved. Possible
critical [bottle-
neck] technology OK 3 21
Proceed to next Possible. Difficult.
step
OK with Not OK
conditions

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Diagnosis Checksheet 8•1 4 - 17

Diagnosis Checksheet

Date of Diagnosis___/___/___
Diagnosed By________________

At stage when production design is complete.
Product: Common

Points Diagnosed: Through the design and prototype manufacture of the planned product, have we
confirmed the suitability of quality and cost, based on customer requirements?

Theme Name:______________________________________________

Development Department Name:___________________________

Results of Diagnosis (Please circle the appropriate answer. Circle the middle answer if neither extreme fits).

Evaluation Item 5 4 3 2 1 Evaluation Comments

1 Determination of All decided. Partial. Basic specs.
No effect may be
production specifications

on equip. changed.

2 Achievement of Achieved Possible Difficult
(≥90%) (≤80%)
performance and reliability (100%)

(rate of achievement)

3 Achievement of critical Achieved Possible Difficult
technology (rate of (100%) (≥90%) (≤80%)

achievement)

4 Achievement of target Achieved Possible Difficult
(≥95%) (≤80%)
cost, estimated value (rate (100%)

of achievement)

5 Outlook on earnings (cost Achieved Possible Difficult
(90-95%) (100%+)
ratio within 3 years) ( ≤85%)

6 Outlook on sales price Agreement Agreement Big gap
from
with customer in-house

desired

customer

Overall Judgment and Comments OK Not OK
Proceed to next step (production design):

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QA Chart Manufacturer:
Model:
Theme Relevant Product:

No. Part Name Quality Standards Points to
Characteristics (when o

Information processing route: design engineering departments (design FMEA) → quali

QA Chart

Date Created Originator Remarks

o Be Aware Of Problems Occurring During
out-of-spec.) Prototype

8•1

ity assurance, production engineering, and manufacturing departments 5 - 18

© JIPM

Quality Assurance System Chart 8•1 5 - 19

Importance Code Foolproofing Rank Code Preparer's Evaluation Code
A-1 Standard type of auto O 100% detectable through
A Cannot achieve the initial
goals. selection, auto stop inspection by special

A-2 Standard type of manual set inspector or A/B-1
foolproofing.
B Characteristics which slightly B-1 Continuous motion type of Quality
∆ B-2 foolproofing, double Syste
affect functions. caution checking

C Almost no relation to B-2 Buzzer and lamp warning X Self-check by operator
performance type of caution

Problem Process Its
Experienced
Foolproofing
Process Process Name Description of Problem Effect of Problem
No. (failure mode) (effect of failure) Standard Type Caution Type

A-1 A-2 B-1 B-2
Importance
Anticipated Problem
Process Itself
Post-Process
Flow-through
Total No.

Code Change Change Date Description of Prepared Approved Code Change Change Date Description of Prepared Approv
No. Change By No. Change By

Quality Grade Product Product No.

Assurance Line Product Name
em Chart

self Pre- and Post-Processes (Process No.) Remarks
Self-Check
Initial Product Pre- Process Name (cause of problems,
Final ProductProcess Process No. countermeasures,
Units/Lot
Random Inspection(sub- etc.)
100% Inspectedassy,
etc.)
Preparer’s Evaluation

ved Overall Eval. Of Control Comprehensive Eval.
Points
Preparer’s Overall
Evaluation

QA Dept. Prod. Engineering Dept. Mfg. Dept. Registration

___/___/___Approved Checked Prepared Approved Checked Prepared Approved Checked Prepared

Registration No.

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Work Standards Sheet 8•1 5 - 20

Work Standards Sheet Line Name Tact Time
No. Major Wor
Process Sequence Process Name Machine Name Machine No. Material
Dwg. Method
3rd Angle Projection

Total
Location

Inspection Item Remarks
Jig/Tool
Location Inspection Item Inspection Value Inspection Tool Inspection Standard

L
Lubricant Name

Eng. Dept., Prod.

Work Procedures Setup Work Contents
rk Time (sec.) Precautions, Other No. Replacement Time

Machining Oil
Name Type Replacement Time Replacement Period

Jig or Jig or Feed Notch RPM Replacement Replacement Remarks
Tool No. Tool
Name Time Period

Lubricant ∇
Fill Location Fill Time ∇

∇

∇

∇

∇

∇ Change Change Change Inspection Desc. Of
Notice No. Entry Date Entered By: Dwg. Change
Change Seq.

Eng. Section Gen. Mgr. Mgr. Subsection Mgr. Insp. Dwg. Mfg.

___/___/___

© JIPM

DR Standards (5th DR Checksheet) 8•1 5 - 21

5th DR Checksheet (Production Preparation)

Product Name DR Member’s Dept.: 　　　　　　　Name:
No. DR Item
1 Evaluation of Check Point Evaluation (5 Levels) Opinion
Reflection of 543
development items pointed Countermeasure 21
progress out in 4th DR Not yet
2 Identification of completed.
production
problems Solution of 5 4 3 2 1
problems during Improved Not yet
3 Evaluation of production trial
trial production
quality Problems in 5 4 3 2 1
processing, Solved Difficult
4. Evaluation of procurement,
maintenance assembly
and safety
Evaluation of 5 4 3 2 1
5. Evaluation of production Complete Not yet
business ability process
drawings.
6. Evaluation of
equipment Evaluation of 5 4 3 2 1
investment plan process Adequate Out-of-spec.
capability
Overall Judgment
Evaluatuin of 54 3 21
reliability of Achieved 3 Difficult
improved areas 54 3
Evaluation of Adequate 3 21
inspection items 54 Unrevisable
and methods Adequate 3
Eval. of quality 54 21
assurance items No prob. 3 Unrevisable
Evaluation. of Possible
problems during 54 21
switch to mass Adequate 95% Mass prod.
production is impossible.
Level of 54
completeness of Adequate 21
service Adequate Incomplete
diagrams
Manuals 100% 21
Incomplete
Outlook on Impossible
target cost ≤ 80%
achievement

Outlook on profit Adequate So-so Impossible
Cost ratio in 3 ≤85 90-95 100+
yrs
Outlook on sales Agree with Agree Big diff. with
price customer in-house customer

Preparation of 5 4 3 2 1
production In place In place Not yet.
equipment & tested.
Proceed to next OK OK with Not OK
step conditions

© JIPM

Diagnosis Checksheet 8•1 5 - 22

Diagnosis Checksheet

Date of Diagnosis___/___/___
Diagnosed By________________
At stage when production preparation is complete.
Product: Common
Points Diagnosed: Based on production trials, production preparation and process evaluations have been
done, and Q, C, D targets for mass production process methods have been met.
Theme Name:______________________________________________
Development Department Name:___________________________
Results of Diagnosis (Please circle the appropriate answer. Circle the middle answer if neither extreme fits).

Evaluation Item 5 4 3 2 1 Evaluation Comments

1 Determination of All decided. Possible with Quality
artial eng. problems.
production specifications

changes. Studying.

(No quality prob.)

2 Achievement of Achieved Possible Difficult
(≥95%) (≤90%)
performance and reliability (100%)

(rate of achievement)

3 Achievement of critical Achieved Possible Difficult
[bottleneck] technology (100%) (≥95%) (≤90%)

(rate of achievement)

4 Achievement of target Achieved Possible Difficult
(≥95%) (≤90%)
cost, estimated value (rate (100%)

of achievement)

5 Outlook on earnings (cost Achieved Possible Difficult
(90-95%) (100%+)
ratio within 3 years) ( ≤85%)

6 Outlook on sales price Agreement Agreement Big gap
with customer in-house from

desired

customer

7 Production process Complete Partial. Not completed.
preparation (including
To be done

standards) by SOP.

8 Production equipment In place In place Major equip.
preparation & tested. Partial test. Not yet in

Done by SOP. place.

9 Establishment of process Established. Possible. Processes
(90-95%) with unstable
assurance (100%)

(comprehensive quality.

evaluation on quality (Studying

assurance system charts) countermeasures)

Overall Judgment and Comments OK Not OK
Proceed to next step (production design):

© JIPM

JIPM - TPM® 600 Forms Manual
Sample Formats for the12 Steps of TPM

8･2 Initial-Phase Equipment Control

© JIPM

8･2 Initial-Phase Equipment Control

Flow

Step Planning Departments Production Engineering Manufacturing Type of Forms
Departments Departmentss

Long-term Business
Goals

1. Planning Concept of Long-term
Equipment Investments

Annual Business Goals

Annual Equipment Investment Plan (budget framework) (1) 1 Annual Equipment Investment
Budget Framework -
Breakdown by Project

Economic Feasibility Study Critical [Bottleneck]

Investment Effectiveness 2 Technology Registration
Target
Control Chart
Grasp of Critical Technology (2)

Development of Critical 3 Critical Technology
Technology Development Schedule
(3)

2. Implementation Plan Development of Equipment

(4)(5)(6)

Establishment of Implementation Plan 4 Process Design Study Sheet
A (Current Processes)

5 Process Design Study Sheet
B (Improved Processes)

Receive Quotations (7) 6 Process FMEA Chart

7 Equipment Quotation
Specifications

Discuss and Decide (8)(9)

8 Equipment Investment Plan

9 Equipment Investment Plan
Details

Determination of Detailed Specifications

3. Design/Manufacturing Issue Order Equipment 10 Equipment Order
Specifications Placement Specifications
(10)(11)
(12)(13) Standards 11 Equipment Introduction and
Inspection/
MP Acceptance Requirements
Information Checksheet
Standards
12 Accuracy Evaluation Chart

13 Equipment/Machinery
Introduction Plan (1) (From
Order Placement to
Introduction and Installation)

Design Engineering (14) 14 Basic Design Checksheet
for Equipment
*

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8･2 Initial-Phase Equipment Control

Flow

Step Planning Departments Production Engineering Manufacturing Type of Forms
Departments Departmentss

3. Design/ * (15) 15 Checksheet of Common
Manufacturing Specifications for Equipment
Manufacturing

(16)(17)(18)

Introduction 16 Equipment Initial-Phase
Evaluation Production
(Commencement/Conclu-
sion) Notice

4. Initial-Phase Production 17 Equipment/Machinery
Introduction Plan (2) (From
Introduction to Mass
Production Evaluation)

Operation 18 EquiippmmeennttPPlalann- -LiLsitsotfof
DocuummeenntstsSSuubbmmittiettdedDuring
Inspection/Acceptance MDuarcihnigneMInatcrhodinuectIinotnroduction
Eval. of Actual Results
(19) 19 Control Standards for
(20)(16) Inspection Standards

20 Equipment Investment
Evaluation Report

5. Operation (19)(20)

Operation, Control

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__ Year ( Period) Equipment Investment Budget

Per Per Budget Per Project Budget Earmarked Funds /2nd Investment Sum
Product Framework Motivation Name Framework Half M
*1 *2 Mil. Y /1st /2nd /1st
No. (¥10,000) Half Half Half

[*1: Guidelines for filling out “Per Budget Framework” column] Budget Framework Categories: A: pr
G: quality control department, H: general affairs department, I: global environment, J: safety environment, K

[*2: Guidelines for filling out “Per Motivation” column] Motivation Categories: 0: TPM, 1: increased p
5: R&D, 6: in-house manufacture, 7: renovation, 8: special investment, 9: other, 10: buildings

Framework - Breakdown by Project Page Annual Equipment Investment Budget
Framework - Breakdown by Project
___/___/___ Strategy
Operations Dept. Category

Investment Effectiveness Target Date:_/_/_

mmary ･ Production capacity, manpower reduction, Decision
Major Equip. improved quality, in-process work reduction, Planned
time savings, expense reduction, other

8•2

roduction equipment, B: TPM, C: R&D, D: CIM, E: Retrofitting, F: engineering division, 1-1
K: workplace environment, L: buildings
production, 2: new/changed specifications, 3: rationalization, 4: quality improvements,

© JIPM

Critical [Bottleneck] Technology Registration Control Cha

Date Prepared
Preparing Dep

Project Name: Product, Part, or Line Name Planned
Content
Critical [Bottleneck] Relevant Diffic
No. Items Fields Ran

(per part, or line)

[Entry Guidelines] 2. Diffi
1. Relevant Field S: Hard-
(1) Processing accuracy and configuration (2) New materials (3) Heat treatment A: Undev
(4) Cleaning, surface treatment (5) Bonding technology (6) Measurement technology B: Not-ye
(7) Sealing method (8) Equipment essentials (9) Other

art Approved Checked Prepared Critical [Bottleneck] Technology
By: By: By: Registration Control Chart
d: _____________________________
pt. _____________________________

SOP:

culty Effect

nk Quality Cost Registration Date Dept. in Charge Deadline Remarks

8•2

iculty Rank 3. Effect 1-2
-to-develop technology Enter a circle in whichever has the greater effect, cost or
veloped technology quality.
et-applied technology
© JIPM

Critical [Bottleneck] Technol

Date Prepared
Preparing Dep

Project Name: Product, Part, or Line Name: Planned

Critical [Bottleneck] Item to be Studied Development Sch
No. Items

[Entry Guidelines]
1. Reporting Periods:

First Time: when functions have been developed
Second Time: when mass production specifications have been determined

logy Development Schedule Critical [Bottleneck] Technology
Development Schedule
d ______________________________ Approved Checked Prepared
pt. _____________________________ By: By: By:

SOP:

hedule Department in Charge Evaluation Remarks

8•2

2-3

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Process Design Study Sheet A Asst
M
Current Processes

Line Name

(1) Process Seq.
(2) Process Name
(3) Machine Name
(4) Manufacturer Name
(5) Process Method
(6) Required Quality

(7) Process Diagram

(8) Type of Problem

(9) Defect Status

(10) Cp Value

(11) Explanation of Problem [1] Fill in everything if different manufacturer’s machines are Pr
Phenomenon/Cause present in the same process. (a
Analysis [2] Fill in from subcontracted processes, and the process sequence (f)
decided by the subcontractot. (j)
Entry Guidelines [3] Fill in the alphabet code shown at right for section (8) problem ac
type. (m
(p
(s

t. Dept. Section Mgr. GL In Charge Process Design Study Sheet A
Mgr. Document No. ________________ (Current Processes)
Date Prepared ________________

Formal Organization Name. ________________

8•2

roblem: 2-4
a) Machine (b) Fixture (c) Tool (d) Cutting (grinding) oil (e) Measurement apparatus
) Inspection tool (g) Process standards (h) Clamp method (i) Locator
) Establishment of process conditions (k) Maintenance, administration (l) Prior process
ccuracy
m) Prior process status (burrs, chips) (n) Loading, conveyance (o) Machine breakdown
p) Minor stoppage (q) Defect losses (r) Startup and yield losses
s) Setup changeover adjustement losses (t) speed losses (u) C/T deviation

© JIPM

Process Design Study Sheet B Asst
M
Improved Process

Line Name

(1) Process
(2) Process Name
(3) Machine Name
(4) Manufacturer Name
(5) Process Method
(6) Required Quality

(7) Process Diagram

(8) Explanation of
Improvement Measures

Proposed Countermeasure
Effect

(9) Equipment Investment [1] In section (1), Process Sequence, mark a star (*) above processes wh
Contents

Entry Guidelines

t. Dept. Section Mgr. GL In Charge Process Design Study Sheet B
Mgr. (Improved Process)

Document No. ________________
Date Prepared ________________
Preparing Dept. ________________

8•2

hich have been improved or added in relation to current processes. 2-5

© JIPM

Product Name: ______________________________ Process FMEA C

Line Name: ______________________________

Process Name: ____________________________

Process Process Name Function Defect Mode Presumed Cause Effec
No.
Effect on Later
Processes

Chart Date: ________________ Process FMEA Chart

Prepared By: ________________

Dept. and Section Name: ________________

ct of Defect Preventative Measure Defect Mode Class Treatment (proposed)

Effect on Product

8•2

2-6

© JIPM

Equipment Quotation Specifications 8•2 2-7

Equipment Quotation Specifications Document No.

Date Prepared: Asst. Dept. Section GL In
Mgr. Mgr. Charge

Equipment Qty.__ machines Formal Name:
Name

Equipment Building Floor Line Process
Location Name Name

Intro. Quotation Planned Order Planned
Schedule Deadline Date Introduction
Date

Relevant Processed Process Reference
Part Name Dwg. No.

Work Type Lot Prior Process
Reference Dwg. No.

C/T (incl. Operating Rate Operating Equip. ___machines
dress.) sec. % Time/Mo. h Capacity/Mo. ___units

Equipment Changeover
Specs. Conditions

Equip. L (length) W (width) H (height) Work Insertion Height Work Extraction Height
Dimensions mm mm mm mm mm

Summary
of

Equipment

Quotation Attachment Method Removal Method
Items
Project © JIPM
Scope

Work Flow Direction

Required
Quality

Spare
Parts

Special
Comments

Equipment Machine Equipment Paint Color

Regulations Plant Equipment Regulations

Equipment Investment Plan 8 • 2 2 - 8 - (1)

Equipment Investment Plan Prepared ___/___/___

Operations Dept.:　　　　　　　 Dept.: GL In Charge
Sect. (G):

Div. Mgr. Dept. Mgr Sect. Mgr.

Year Framework Name Year Frame. No.

This Plan Name No. of Units Planned

Budget Budget for Plan Working Budget Equip.
(¥ mil. ) (¥ mil. ) Location

Control Team Expense Team Line Team

Motivation 0 1 2 3 4 56 7 8 9 10

Category TPM Prod. New or Rationalization Improved R&D In-house Renovation Special Other Building

Increase Changed Qual. Mfg. Invest.

Specs.

In-house/ 1 In-house Qty. ¥ Amount Planned Order Placement Planned In-Stock Planned
Outsourced 2 Outsourced Project
Date:_/_/_ ¥ Amount Date:_/_/_ ¥ Amount Completion
Mfg. (Domestic)
Categoory Date:_/_/_

3 Outsourced

(Imported)

1. Background Explanation and Purpose

2. Contents of Plan

Safety Check (during Registration with Qualified Personnel Pollutants Special Explanation about Equipment Specs.
equipment planning) Govt.

Req. • Not Req. Req. • Not Req. Present/Absent Present ( ) • Absent

(Suspended • Reallocated • Discarded (partially discarded) Machinery) (Unit: Yen thousand)

Machine Name Control No. Acquisition Date Acq. Cost Book Value Deprec. Rate Machine Reallocation Plan No.

%

Attached Documents (1)________________ (2)________________ (3)________________ (4)________________
(5)________________ (6)________________ (7)________________ (8)________________

© JIPM

Equipment Investment Plan 8 • 2 2 - 8 - (2)
(continued)

3. Targets (To establish target values related to QCD).

Item Current Status After Introduction

Production Capacity
Personnel
Cycle Time
Man-hours
Operating Rate
Product Function
No. of Complaints
Rate of Non Thru-put
Process Capacity
Cleanliness
Lead Time
In-process
Space
etc.

4. Effect and Return Period

Product Life Years
Equipment Life Years

Sales Price
Quantity Sold

Non-monetary Effects Return Period
A Less than 3 years
B Between 3 and 5 years
C More than 5 years
D Strategic investment

5. Problems if Investment Not Made 6. Other Alternatives and Effects

7. Uncertain Factors 8. Problems, Critical [Bottleneck] Technology

© JIPM

Equipment Investment Plan Detail

Prepared
Operations Div

Equipment Contents Budget-related

Machine Qty. Motiv. In-house/ Planne Planned User Line Year Equip. Plan Wo
Equipment Frame Plan Budget Bud
Categ. Outsource d Order Insp./Acce Team No.
Name No. (Yen million
Category pt. Name

___/___/___ Dept. Mgr. Sect. Mgr. GL In Charge Equipment Investment Plan Detail

v. Dept. Sect. (G)

Machine Operating Plans Effect

orking Machine Cycle Machine Pace Machine Planned Return on Personnel Remarks
dget Time Oper. Time Capacity Reduced
(sec.) Rate (sec.) Oper. Time Investment
n) (%)
(hr./month) (%)

8•2

2-9

© JIPM

Equipment Order Placement 8•2 3 - 10
Specifications

Equipment Order Placement Specifications Equipment Plan No..

Date Prepared: Formal Name

Asst. Dept. Mfg. Improved Insp. Prod. Sect. GL In
Mgr. Eng. Mgr. Charge
Equipment Qty. __ machines

Name

Purchase Manufacturer Trading Co.
From Name Name

Intro. Manufacturer Introduction Operating Inspect/Accept-
Schedule Meeting Date Date Date ance Date

Relevant Processed Process Reference
Part Name Dwg. No.

Work Type Lot Prior Process
Reference Dwg. No.

C/T (incl. Operating Rate Operating Equip. ___machines
dress.) sec. % Time/Mo. h Capacity/Mo. ___units

Equipment Changeover
Specs. Conditions

Equip. L (length) W (width) H (height) Work Insertion Height Work Extraction Height Height of Lower
Dimensions mm mm Operating Panel Surface

mm mm mm mm

Summary
of

Equipment

Project Attachment Method Removal Method
Scope
Meeting Location
Work Flow Direction
Supply Trading Company
Parts

(Quantity,
Timing)

Spare Parts

Special
Comments

Equipment Machine Equipment Paint Color
Regulations

Agreement Plant Equipment
Regulations

Attendees Meeting Date

Signatures Manufacturer

© JIPM

Equipment Introduction and Inspection/Acceptanc

Managing Dept.

Machine Name Processed Part Name
Pre-meeting Eval. Date
Manufacturer Meeting Eval. Date In
No. Evaluation Item
Evaluation Steps Evaluation Method Pre-m

Pre-Mtg.Eval. Mfg. Mtg. Eval. In-house Mtg. Eval. Resu

Comments {1} Condition for deciding whether or not to meet: pre-meeting evaluation items
{2} Condition for introduction: manufacturer meeting evaluation items must be
{3} Condition for inspection/acceptance: in-house meeting evaluation items mu

ce Checksheet Equipment Introduction and
Inspection/Acceptance Checksheet
Production Eng. Gr Equipment Plan No.

Process Name Sect. Mgr. GL In Charge

n-house Meeting Eval. Date

meeting Evaluation Check Manufacturer Meeting Check In-house Meeting Check Remarks

ults Evaluation Results Evaluation Results

8•2

must be satisfied. (Done by manufacturer). 3 - 11
satisfied.
ust be satisfied.

© JIPM

Accuracy Evaluation Chart

Managing Dept.

Machine Name Processed Part Name

Pre-meeting Eval. Date Manufacturer Meeting Eval. Date In

Location Guarantee Pre-meeting Ma
No.
Evaluation Item Standard Value Cp Total Eval. Qty. Sampling Results Eval. Qty

Qty. Method Check

Comments

Sampling No. Sampling Method Sampling No. Sampling Method Process
A A
B B
C C